Floor covering for an animal house

ABSTRACT

Floor covering (I) for an animal house for beef animals and dairy animals comprises an elastomeric mat ( 2 ) which can be fixed to a floor or floor slat by screws ( 8 ). Rigid strips ( 6 ) are located at the base ( 7 ) of mat ( 2 ) for securing the screws ( 8 ) which are coverable by the mat when it is fixed to the slat. Mat ( 2 ) is designed for cleanliness and enhanced protection and comfort for animals. Flap valve ( 3 ) forms an openable flap valve along one longitudinal edge of the mat ( 2 ) to seal a gap between adjacent slats of a slatted floor to reduce the emission of gases and fumes emanating from a tank beneath the floor. The flap valve ( 3 ) allows waste material to pass through the slatted floor to the tank.

BACKGROUND OF THE INVENTION

The present invention relates to a floor covering for the protection andcomfort of animals, such as beef animals and dairy animals, in an animalhouse and more particularly to improvements in and relating to mats forconcrete floors or concrete slats of slatted houses, for standing areasin animal houses, around feed and water stations, and the bases ofcubicle entrances.

It is known to place a mat comprising a rubber strip onto the concreteslats in slatted houses used for housing cattle. The known mat issecured on the concrete slat by either tying the mat on to the slatusing a wrap around band or by directly screwing the mat into theconcrete slat. Securing the mat using the band has not proved to besuccessful primarily because the band can become damaged. Furthermorethe mat is not fully secured to the slat and the mat is likely to comeloose and become slideable relative to the slat.

The disadvantage of screwing this type of mat into the concrete slat isthat the exposed screws can pose a hazard either when an animal kneelsdirectly onto the screws resulting in injury to the animal or if andwhen the screw rusts, again posing a danger to the animal. A more recentattempt of overcoming the problem involves the use of rubber stripsattached by means of a bung or clip. For this system to functionproperly, the concrete flooring would need to be completely uniformwhich does not happen in practice.

The mixture of manure, urine and silage effluent that flows into aslurry tank beneath an animal house produces hazardous gases whichcontinually disperse up through the gaps in the concrete slats andcirculate around the slatted house. These gases are detrimental to thewelfare of the animals that are housed under these conditions and to thefarm workers who take care of the animals on a daily basis.

None of these prior art systems address the comfort and protection ofthe animal or assist in dealing with hazardous gases. In order toimprove the protection and comfort of animals on concrete and concreteslatted floors while maintaining the proven features of such floors, afloor covering which provides a more beneficial animal floor surface wasproposed by the inventor of the present invention in Irish Short-TermPatent Application No. S990443 and International Patent Application No.PCT/IE99/00098. The floor covering disclosed in these applicationscomprises elongated strips of elastomeric material engageable inseparate housings fitted to each separate slat.

However, a number of problems subsist in the technical solutions inIrish Short-Term Patent Application No. S990443 and International PatentApplication No. PCT/IE99/00098. The elongated strips of elastomericmaterial are difficult to secure to the housings and their installationis labour intensive.

SUMMARY OF THE INVENTION

The present invention seeks to alleviate the disadvantages associatedwith the prior art and the problems associated primarily with slattedfloors and also concrete floors.

Accordingly, there is provided a floor covering for an animal houseadapted to provide comfort and protection for beef and dairy animalscomprising an elongate elastomeric mat adapted to be fixed to a concretefloor or a concrete floor slat by fixing means, the mat having anintegral rigid portion for receiving the fixing means which arecoverable by the mat when it is fixed to the slat, without detractingfrom the protection and comfort given to the animals.

Advantageously, the mat has an openable elongate flap valve extendingfrom at least one longitudinal edge of the mat for sealing a gap betweenadjacent slats of a slatted floor.

A floor covering of this type with a flap valve can reduce harmful gasand odour emissions which are continuously circulating around a householding animals which are housed in holdings of this type. Any reductionin gas emission is of benefit to farm workers who spend a considerableamount of time in the slatted house taking care of the housed animals,or who are in the animal house during mixing and emptying the slurrytank at various times of the year. Additionally, the unitary nature ofthe mat reduces the complexity of assembly of the floor covering therebyreducing the installation time for farmers. A one-piece mat also removesthe possibility of relative movement between a housing member and ahoused strip preventing injury to the housed animals as a result of themloosing their footing.

Preferably, the mat is formed using a multi-extrusion process. Usingthis technique, components of the mat can be formed separately insidethe tool and then co-extruded together in a final step of the overallprocess.

Optionally, the components are formed from different materials or fromthe same materials having different densities. This allows themanufacturer to alter the physical properties of the product dependingon customer requirements.

Ideally, the width of the entire extrusion may be varied by varying thespeed of extraction of the materials forming the component parts of thefloor covering.

In a particularly preferred embodiment, the mats are extruded having aplurality of longitudinally extending cavities to maximise comfort. Thisallows the product to have an increased protection and comfort whilstincreasing the shock absorbent properties of the mat with the inclusionof the central cavity.

In one embodiment, the main body comprises a high content of nitrilerubber or a similar material with a high compression set which givesgood shock absorbency in the finished mat.

In a particularly preferred embodiment, a hard-wearing durable materialis used to provide the outer surface of the main body of the mat. Thisprovides a further layer of protection for the product against thesubstantial impact forces imparted by the housed animals.

Preferably, the rigid portion is provided by a number of longitudinalrigid strips which are co-extruded with the mat in a final step of theoverall manufacturing process.

Ideally, the rigid strips are co-extruded during manufacture onto thebase of the mat and are uniformly distributed about the base to evenlydissipate the load applied about each connection between the mat and theslat or concrete floor. This prevents an uneven distribution of loadabout any individual connection preventing excessive wear and tear aboutthat particular connection.

Advantageously, the mat is manufactured from a non absorbent materialand has a domed profile in order not to react with or retain animalurine and dung, thereby assisting in improving the cleanliness of thehoused animals.

Preferably, the rigid strips act as washers for the fixing meansincreasing the strength of the connection between the mat and the slator concrete floor. The elastomeric mat is subjected to considerablestress and strain due to the uneven weight distribution of animalsmoving about on the mats. Providing rigid strips along the entire lengthof the mats prevents the elastomeric mat from easily tearing away fromthe fixing means and slat.

In a particularly preferred embodiment, the location of the rigid stripson the base of the mat is indicated on the top surface of the mat. Thisprovides a means for identifying the location of the strips to assist infixing the mats to the slats.

Ideally, the barrier is provided by a flap extending from onelongitudinal edge of the mat. It will of course be appreciated that theflap could extend from either longitudinal edge or both longitudinaledges of the mat.

Preferably, a groove extends longitudinally intermediate the flap andthe mat providing a hinge for the flap.

In one embodiment, the flap extends under the bottom surface of theadjacent slat forming a seal.

Ideally, the fixing means is provided by self-tapping screws, masonrynails or any other fixing means which may be applied through theelastomeric mat, lodged in the rigid strips, secured into the concreteslat or concrete floor and are covered over by the elastomeric mat sothat animals cannot come in contact with the fixing means.

In a particularly preferred embodiment, the rigid strips are verticallyaligned with a number of central cavities allowing the fixing means topass through the outer skin into the central cavities and to lodge intorigid strips. The heads of the fixing means will not remain proud in thecavity when the fixing means are fully installed.

In one embodiment, a number of longitudinal grooves are provided on thebase of the mat. These grooves increase the flexibility and shockabsorbent capabilities of the mat. The grooves provide that a solidpiece of material will not extend from the top to the bottom of the mat.This reduces the overall impact forces transmitted to the housed animalswhen compared with a completely solid mat.

Installation of the mats requires a user to fix the mats to the slatswith their flap valves extending in the same direction. Ideally only oneflap valve is required on each mat when this technique of installationis used.

Alternatively, the mats may be fitted in either direction when a flapvalve extends from both longitudinal edges of the mat.

Ideally, the mats are formed using different materials. The mats may beformed from a rigid material or a soft material depending on theirparticular function.

Ideally, the mats are manufactured from any extrudable rubber orsynthetic material.

The present invention also provides a mat for use on concrete slats inslatted houses comprising a flange provided along two opposing edges ofthe mat, through which flange a fixing means can be inserted so as tosecure the mat onto the concrete slat and further comprising a flapprovided along said two opposing edges of the mat, the flap beingmovable between an open position and a closed position whereby in theopen position, the flap is lifted up and the flange is exposed so thatthe fixing means can be inserted into the flange and in the closedposition, the flap is lying down over the flange thereby covering overthe fixing means inserted through the flange.

Ideally, the mats are formed using different materials. The mats may beformed from a rigid material or a soft material depending on theirparticular function. In a preferred embodiment, the mats are extrudedhaving a central core and a covering skin, This allows the manufacturerto use an inexpensive material for the core and then cover the core witha rigid skin.

Advantageously, in one embodiment of the mat, a shock absorbent materialmay be located underneath the mat and is securable thereto.

In an alternative embodiment of the mat a plurality of ridges may beprovided on the underneath of the mat to provide a cushioning effect.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described with reference to the accompanyingdrawings, which show, by way of example only, a number of embodiments ofa slatted house floor covering in accordance with the invention inwhich:

FIG. 1 is a cross sectional view of a first embodiment of a floorcovering having a domed surface for cleanliness and with the securingscrews shown proud and before final installation; and

FIG. 2 is a cross sectional view of a second embodiment of floorcovering showing the screws lodged in position in the rigid strips;

FIG. 3 is a cross sectional view of a third embodiment of floorcovering;

FIG. 4 is a cross sectional view of a fourth embodiment of floorcovering which is designed for use on concrete floors and has particularapplication for dairy cows;

FIG. 5 is a cross sectional view of a fifth embodiment of floorcovering;

FIG. 6 is a side elevation view of a manure scraper modified toaccommodate the floor covering of the invention

FIG. 7 is a side view of a sixth embodiment of mat of the invention;

FIG. 8 is an enlarged side view of one of the edges of the mat showingthe flange and flap of FIG. 7

FIG. 9 is an enlarged side view of one of the edges of the mat showingthe flap in the open position and showing a screw inserted through theflange;

FIG. 10 is an enlarged side view of one of the edges of the mat showingthe flap in the closed position in which it covers over the flange andthe screw inserted therethrough;

FIG. 11 is a side view of the mat in use with a sheet of shock absorbentmaterial located under the mat and secured to the mat and to theconcrete slat;

FIG. 12 is an enlarged side view of the mat of the sixth embodimentshowing a screw inserted at an angle into the flange;

FIG. 13 is a side view of a seventh embodiment of the mat in which aplurality of ridges are provided on the underneath of the mat.

FIG. 14 is a side view of the mat and shock absorbent material locatedon an individual concrete slat;

FIG. 15 is a side view of an eighth embodiment of the mat in accordancewith the invention; and

FIG. 16 is a schematic diagram of the prior art mat located on anindividual concrete slat and showing a screw and a band, used in theprior art.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings and initially to FIG. 1 there is shown a floorcovering indicated generally by the reference numeral 1. The floorcovering 1 is provided by a domed mat 2 having a flap valve 3. A groove4 is located between the flap valve 3 and the mat 2 to provide a hinge.The mat 2 has a number of central cavities 5 extending longitudinallythrough the mat 2. Three rigid strips 6 which act as anchors for screws8 are located about the base 7 of the mat 2. Three screws 8 e.g.self-tapping screws are screwed through the mat 2, the central cavities5 and the rigid strips 6 providing a secure connection between the mat 2and the slat (not shown). When completely screwed in the heads of thescrews 8 are buried into the strips 6 which also retain the shape of themat.

A pair of parallel lines 15 are located on the upper surface of the matto indicate the location of the strips 6 on the bottom surface. Thescrews 8 are inserted between the indicating lines 15 and the materialcloses back over again after the screws have been inserted.

As shown in FIG. 1, the edges of the mat are inclined at an angle a fromthe bottom surface of the mat. This creates a improved seal with thefloor and ensures that the edges of the mat grip the floor and are notinclined to turn upwards. The surface of the mat 2 is domed so that itdoes not retain animal urine and dung on its surface which will wash offeasily. Also the mat is made of a non-absorbent material which will notreact with the urine and dung.

Referring to the drawings and now to FIG. 2, the features of the secondembodiment which correspond with and are identical to features of thefirst embodiment are referenced by identical numerals. The floorcovering indicated generally by the reference numeral 1 also includes anumber of longitudinally extending grooves 11 located on the base 7. Thegrooves 11 prevent direct contact between the mat 2 and the concreteslat reducing forces transmitted to the housed animals. Two extracentral cavities 5 are also included in the mat 2. Screws 8 are shownfully lodged into the strips 6.

In use, an operator locates each mat 2 about the top surface of a slatand pushes the flap valve 3 into the gap between the supporting slat andthe adjacent slat. The flap valve 3 rests against the bottom surface ofthe adjacent slat or against the sidewall of the adjacent slat sealingthe gap therebetween. Ideally, for slatted floors each mat 2 should bemounted with the flap valve 3 facing in the same direction. The operatorcan now fix the mat 2 to the slat by driving screws or nails 8 into themat 2 and through the central cavities 5, rigid strips 6 and finallyinto the concrete slats. The self-tapping screws 8 are forced into themat 2 until the screw heads are located within the rigid strips 6. Thisreduces the risk of an animal hurting itself on an exposed screw or nailhead. The flap valve 3 flexes under the weight of waste material toallow the waste material to pass through the gap and then returns to anormally closed position to seal the gap. This reduces gas and odouremissions from a slurry tank below the ground ascending through the gapsbetween adjacent slats and into a house above the slatted floor. Slitscan be provided along the length of the flap valve 3 at specifiedintervals so that only a portion of the elongate valve will open asrequired. If not required the flap valve 3 can be trimmed off or turnedunder the mat.

The third embodiment 300 shown in FIG. 3 is similar to the first andsecond embodiments and like features are given like numerals. The mat 2has a flap valve 4, a number of central activities 5 and three rigidstrips 306 for securing the mat in position. Each strip 306 has a pairof lugs 307 to provide a secure anchoring with the main body of the mat2.

The mats may also be joined in contiguous fashion where edges of eachadjoining mat contact one another. The flap valves 3 may be insertedunder each neighbouring mat or may be removed if desired. Thisarrangement is particularly beneficial where animals stand adjacent tofeed and water stations. It may also be used to provide a comfort zonefor animals standing on bare concrete floor or bare concrete slats.

The fourth embodiment 400 shown in FIG. 4 which is particularly usefulfor dairy cows comprises a mat 402 which has a sloped section 403 at oneside and a generally straight section 404 at the other side. Thestraight section 404 has a slightly tapered side wall 406 which ensuresa good fit against a concrete strip or ledge as used in an animalcubicle shed and which are generally irregular in shape. The fourthembodiment 400 also includes central cavities 5, three rigid strips 6and longitudinally extending grooves 11 located on the base 7. Theembodiment 400 can be used in animal houses or portions of animal housesnot having a slatted floor surface such as passageways between rows ofcubicles and feeding areas in animal houses. The embodiment 400 providesa particularly beneficial shock absorbing mat for bovine cows whenreversing out and down from a cubicle when the mat 402 is installed as acubicle kerb. Observations from field tests have shown that the loadtaken by the hind claws of cows when reversing or slipping out fromcubicles to be a very significant cause of lameness. The mat 402provides a cushioned gripping surface for the cows' claws and the shapeof the mat allows the claws to open and close correctly and naturally,thereby helping to prevent lameness. To protect a damaged claw a cow canstand so that only one half of a claw stands on the mat 402 with theother half of the claw suspended so as to take pressure off the damagedclaw.

In the fifth embodiment 500 shown in FIG. 5, which is similar to thefirst, second and third embodiments, the securing strips of the firstthree embodiments are replaced by three elongate anchoring formations506 which secure the mat 502 to a concrete floor slat while the slat isbeing formed from wet concrete. The anchoring formations 506 are T-barsextending from the rigid strips and can have different shapes. Using theembodiment, the concrete floor slats are supplied with the mats alreadyinstalled.

When mats according to the invention such as the embodiment 400 aresecured in the passageways of cubicle houses which have scraper systemsinstalled for the management of manure, it is necessary to modify thescraper for 551 to accommodate the mats located lengthwise along thepassageway by providing cut outs 552 in the bar. A cut-out 553 is alsoprovided in the wing 554 to accommodate a mat located to one side of thepassage way. Pulling mechanism 555 draws the scraper 551 along apassageway.

Referring to FIGS. 7 to 12, the sixth embodiment of the mat of theinvention is indicated generally by reference number 601. The mat 601comprises a flange 602 and a flap 603 which are provided along thelength of both major edges of the mat 601. The flap 603 and flange 602are formed by a slot 604 made in the mat 601.

In use, the mat 601 is placed on a concrete slat 606, the flap 603 islifted up into the open position as shown in FIG. 9 and a number ofscrews 605 are inserted through the flange 602 along the length of themat 601 at both major edges, thereby securing the mat to the concreteslat 606. The flap 603 is then lowered to the closed position as shownin FIG. 10 and the screw is covered thus protecting animals from injuryand preventing the screw from rusting.

A shock absorbent material 608 may be placed underneath the mat 601 asshown in FIG. 11. The shock absorbent material 608 offers protection tothe mat 601 and the shock absorbent material 608 is secured by the mat601 lying thereon and by the screw 605.

It will be appreciated that the shock absorbent material 608 may beinserted as a separate sheet under the mat 601 or may be attached to themat 601.

A seventh embodiment of the mat is shown in FIG. 13. The mat of theseventh embodiment is indicated generally by reference numeral 721. Themat 721 includes a flap 723 and a flange 722 which have the same formand function as described above in relation to the sixth embodiment. Themat 721 is provided with a plurality of ridges 727 on the underside ofthe mat 721. The ridges 727 provide a cushioning effect for the mat 721and provide an alternative to the inclusion of the shock absorbentmaterial 608 referred to above.

Referring finally to FIG. 15, there is shown an eighth embodiment of themat 831 formed using a multi-extrusion process. The main body 832 of themat 831 is extruded in one piece and the flaps 833 are both extrudedseparately. In a final step of the multi-extrusion process the flaps 833are co-extruded with the main body 832 of the mat 831 completelycovering the flanges 834. The mat 831 is provided with a plurality ofridges 837 on the underside of the mat 831. The ridges 837 provide acushioning effect for the mat 831.

It will of course be understood that the invention is not limited to thespecific details as herein described, which are given by way of exampleonly, and that various alterations and modifications may be made withoutdeparting from the scope of the invention as defined in the appendedclaims.

1. A floor covering for an animal house adapted to provide comfort andprotection for beef and dairy animals, comprising: an elongateelastomeric mat; and means for fixing the mat to a concrete floor or aconcrete floor slat; the mat having an integral rigid portion forreceiving the fixing means such that the fixing means are coverable bythe mat when the mat is fixed to the slat, without detracting from theprotection and comfort given to the animals.
 2. A floor covering for ananimal house as claimed in claim 1, in which the mat has an openableelongate flap valve extending from at least one longitudinal edge of themat for sealing a gap between adjacent slats of a slatted floor.
 3. Afloor covering as claimed in claim 2, wherein the flap valve is providedby a flap extending from one longitudinal edge of the mat.
 4. A floorcovering as claimed in claim 3, wherein the flap extends under a bottomsurface of an adjacent slat forming a seal.
 5. A floor covering asclaimed in claim 3, wherein the flap extends down and across the gapabutting against a sidewall of the adjacent slat forming a seal.
 6. Afloor covering as claimed in claim 3, wherein a groove extendslongitudinally intermediate the flap and the mat to provide a hinge forthe flap valve.
 7. A floor covering as claimed in claim 1, wherein themat is formed using a multi-extrusion process.
 8. A floor covering asclaimed in claim 7, wherein the width of the entire extrusion isvariable by varying the speed of extraction of the materials forming thecomponent parts of the floor covering.
 9. A floor covering as claimed inclaim 7, wherein the mat is extruded having a covering main body and afixing means and the main body has a plurality of longitudinallyextending central cavities.
 10. A floor covering as claimed in claim 9,wherein the main body comprises a high content of nitrile rubber or asimilar material with a high compression set which gives good shockabsorbency in the finished mat.
 11. A floor covering as claimed in claim3, wherein the rigid portion is provided by a number of longitudinalrigid strips which are co-extruded with the mat.
 12. A floor covering asclaimed in claim 11, wherein the rigid strips act as washers for thefixing means and also act as supports to retain the shape of the mat.13. A floor covering as claimed in claim 11, wherein the rigid stripsare co-extruded onto a base of the mat and are uniformly distributedabout the base to evenly dissipate the load applied about eachconnection between the mat and the slat.
 14. A floor covering as claimedin claim 11, wherein the mat has a number of central cavities and therigid strips are vertically aligned with the central cavities tomaximize comfort of the animals and to allow access for the fixingmeans.
 15. A floor covering as claimed in claim 11, wherein the locationof the rigid strips on the base of the mat is indicated on the topsurface of the mat to provide a guide for the fixing means.
 16. A floorcovering as claimed in claim 1, wherein the rigid portion is provided bya number of longitudinal rigid strips and the fixing means is providedby fasteners which may be applied through the elastomeric mat, embeddedin the rigid strips and secured into the concrete slat.
 17. A floorcovering as claimed in claim 1, wherein a number of longitudinal groovesare provided on the base of the mat.
 18. A floor covering as claimed inclaim 1, wherein the mat is formed using materials of variable rigidity.19. A floor covering as claimed in claim 1, wherein the mat ismanufactured from any extrudable rubber or synthetic material.
 20. Afloor covering as claimed in claim 1, wherein the mat is manufacturedfrom a non-absorbent material in order not to react with, and has adomed profile in order not to retain, animal urine and dung therebyassisting in improving the cleanliness of the housed animals.
 21. Afloor covering as claimed in claim 1 in which the edges inclined at anangle from a bottom surface of the mat, thereby creating an improvedseal with the floor or slat and ensuring that the edges of the mat gripthe floor and are not inclined to turn upwardly.
 22. A floor covering asclaimed in claim 1 in which the mat is provided with a tapered side wallto ensure a good fit against an irregularly shaped concrete structuresuch as a base of an animal cubicle wall.
 23. A floor covering asclaimed in claim 1 in which the mat includes a surface adapted tosupport an animal's claw and allow it to function naturally.
 24. A floorcovering as claimed in claim 1 in which a surface of the mat is slopedto one side to prevent urine and dung from being retained on the mat.25. A mat for use on concrete slats in slatted houses, comprising: amain body having two opposing edges; a flange provided along the twoopposing edges of the main body of the mat; a fixing means insertablethrough the flange so as to secure the main body of the mat onto theconcrete slat; and a flap provided along said two opposing edges of themain body of the mat, the flap being moveable between an open positionand a closed position whereby in the open position the flap is lifted upand the flange is exposed so that the fixing means can be inserted intothe flange and in the closed position the flap is lying down over theflange thereby covering over the fixing means inserted through theflange.
 26. A mat for use on concrete slats as claimed in claim 25, inwhich the mat is formed using different materials, the mat being formedfrom a rigid material or a soft material depending on its particularfunction.
 27. A mat for use on concrete slats as claimed in claim 25 inwhich the mat is extruded having a central core and a covering skin,thereby allowing a manufacturer to use an inexpensive material for thecore and then cover the core with a rigid skin.
 28. A mat for use onconcrete slats as claimed in claim 25, in which a shock absorbentmaterial is located underneath the main body of the mat and is securablethereto.
 29. A mat for use on concrete slats as claimed in claim 25, inwhich a plurality of ridges are provided on an underneath of the mainbody of the mat to provide a cushioning effect.